SARAS Technology

Key Skills Mix

Company Name: SARAS Technology

Website: http://sarastech.co.uk/

Project Title: 2D to 3D CAD translation of X-band power amplifier [Service]

Dates: October 2015 - November 2015

Location: Leeds, West Yorkshire, U.K.

World-class RF & Microwave capability. Custom Engineering for a safer world. High-performance, cost-effective design. Partnering major Defence and Security organisations and OEMs worldwide.
Source: https://www.sarastech.co.uk/

Working closely with Saras Technology technical director to translate their customers’ requirement in 2D AutoCAD drawings into a 3D assembly suitable for manufacture with product visuals for customer presentations.

Inca Digital Printers

Company Name: Inca Digital Printers

Website: www.incadigital.com

Job Title: Mechanical Design & Automation Engineer (Contract)

Dates: 14/11/17 to 22/02/17

Location: Cambridge, UK.

“Inca Digital Printers is an industry leader in the design, development and manufacture of inkjet printers for the print industry.

To date, this work has focused on equipment for the POS sector, but the technology is also suitable for other industrial applications and is an important area for future growth.

Inca Digital was the first company to design and manufacture a moving table flatbed printer for the printing industry in 2001 with the Eagle 44. Since then, the company has proved itself as an innovator and leader in the field of inkjet producing another eleven machine model designs to date, resulting in industry acclaim.

In 2007, the launch of the Inca Onset created a paradigm shift in digital print quality delivering a digital press that for the first time could really take screen printing volume and that would become a real workhorse for its owners.

Since the launch of the Onset, Inca has expanded its range with the Onset S20i, Onset S40i,Onset Q40i, Onset S50i, Onset R40i and Onset R50i. With this ongoing product development Inca continuously seeks new solutions to the challenges their customers encounter”.
source: www.incadigital.com

Working with a team of R&D engineers over a wide range of specialities including mechanical, electrical, controls, electronics and software developing a new format commercial digital printer. My role included;

Translating the conceptual industrial design for new machine enclosure into engineering product with consideration of materials selection for chemical compatibility, manufacturability, production assembly, design for freight/container transport, service & maintenance.
General mechanical engineering support including part, assembly & drawing creation, update & management to Inca’s best practice guidelines.
Working from a blank sheet to design multipurpose sheet & panel feeder working over wide range materials and thicknesses from 120 gsm paper up to 1/2" thick wood panels.

SARAS Technology

Company Name: SARAS Technology

Website: http://sarastech.co.uk/

Project Title: Design & prototype manufacture of finishing and testing equipment for 60MHz LE filter (Service)

Dates: June 2016 - November 2016

Location: Leeds, West Yorkshire, U.K.

Key Skills Mix

World-class RF & Microwave capability. Custom Engineering for a safer world. High-performance, cost-effective design. Partnering major Defence and Security organisations and OEMs worldwide.
Source: https://www.sarastech.co.uk/

Full turnkey service for the design, prototype and manufacture of 60 MHz LE filter finishing and testing equipment. Working from an outline specification and anticipated production volumes, I was responsible for the full process from creating the proposal, statement of work and project plan.

Through concept generation, engineering design and detailing, CAE analysis, component sourcing, build and test, providing 3D visualisations and update presentations throughout the process to ensure client engagement.

Kinetic Traction Systems

Company Name: Kinetic Traction Systems Inc.

Website: www.kinetictraction.com

Job Title: Consultant Design Engineer

Dates: September 2014 - August 2016

Location: Bristol, UK; Deeside, Flintshire, UK & Chatsworth, CA, USA

Key Skills Mix

"Founded in 2010, Kinetic Traction Systems, Inc. (KTSi) designs, develops and manufactures clean technology products for energy storage, power regeneration, waste heat recovery and turbo aeration applications. Product development is based on proprietary know-how and expertise in high-speed permanent magnet motors, magnetic bearings, power electronics and controls combined with advanced analytical capabilities. Kinetic Traction Systems’ products are designed to improve performance and efficiency, reduce energy consumption and lower carbon emissions, while providing innovative solutions to a variety of applications and industries in global markets. KTSi headquarters, research and development, and manufacturing are located in Chatsworth, California, USA with a design and application center in North Wales, UK."

Source: http://kinetictraction.com/

I first started working with KTSi after being approached for a position to work with a small project team of highly skilled external contractors from the likes of Williams F1 & Micheal Butler Creative.

Over the years I've worked on a number of projects and most recently on the design and development of a 4000 SCFM high speed centrifugal fan, with applications in the waste water and processing industries. For details of my involvement in each project please see below.

300 kW Waste Heat Recovery Generator (Organic Rankine Cycle)

KTSi - Waste Heat Recovery Generator Close Up

I joined the WHRG project team in the later stages of the development process. Much of the design direction had already been defined and a manufacturing of the key components underway. My role was to assist the engineering team in the translation of the design and assembly intent into manufacturable components and subsequent technical documentation.

Due to the large forces involved and temperature differential between components - such as the generator stator and ductile cast iron housing - a number of critical limits and fits required defining. Using a combination of mathematical and computer aided numerical techniques I worked to define robust connections, taking into account machining capabilities for each of the critical interfaces. Examples of challenges I was responsible for solving include;

Detailed analysis of interference fits in a R-245fa pressurised environment using standard mathematical models and finite element analysis.
Assembly tooling design, development, testing & producing manufacturing packs.
GD&T utilising Solidworks DimXpert & TolStack for tolerance stack analysis.
Cost down activities such as replacing high cost per part metal components with polymer parts incorporating structural bonding.
Bolted joint analysis for key structural connections.

4000 SCFM Turbo Aerator

I began working on the development of the Turbo Aerator early in the product design cycle. Working with KTSi's engineering teams both in the USA & UK, as well as with specialist external suppliers we worked from first principles to design from the ground up a high speed centrifugal fan offering higher efficiency at increased turn-down ratios predominately for use in the waste water processing industry.

My focus were mainly on the mechanical, thermal and fluid flow aspects of the system's design but worked in conjunction with the external suppliers for key components such as the impeller and the 5 axis active magnetic bearing (AMB) system, both bespoke . Due to the high speed nature of the machine (27 krpm), structural dynamics played a key factor in the development of the rotating components as well as the bearing system, auxiliary bearing system and aluminium sand cast housing. Utilising computer aided engineering tools I ran multiple design schemes for shaft design and component configuration, minimising the effect of the overhung mass and ensuring shaft critical outside the operating range of the machine.

My involvement in the design and development of the machine incorporated all aspects from concept to assembly including;

Shaft design for structural integrity and dynamic performance.
Translating volute scroll geometry into sand casting minimising hydraulic losses.
Design of split housing sand casting incorporating conductive and convective thermal pathways for motor cooling.
Design for manufacturing - high speed rotating components, shrink & interference fits, castings, fabrications, pipework & electromechanical systems.
Design for assembly - non contact sensors, AMB system integration, cable routing, sealing, environmental packaging.

Form Lab

Key Skills Mix

Company Name: Form Lab Ltd.

Website: www.theformlab.com

Job Title: Technical Director (Owner)

Dates: January 2012 - present

Location: Leeds, West Yorkshire, UK.

Form Lab is a product design and engineering consultancy based at Duke Studios in Leeds, West Yorkshire. We're a micro consultancy offering a range of design and engineering services to larger consultancies and companies involved in the design and development of products across a wide range of industries. To date we've been lucky enough to have worked with some big names on some truly game changing products. You can see examples of my involvement as well as other projects I've delivered in the portfolio section of this site.

I started Greener Designed Ltd. back in Jan 2012 (as was called then) with the vision of building a cleantech company capable of taking an idea and developing it in to a fully fledged sale-able product. By offering design and engineering services to clients we could use the profits generated from these sales used to fund the development of our own products. We re-branded in January 2015 from Greener Designed Ltd. to Form Lab Ltd. with the help of local design agency Passport to give our consultancy services wider market appeal. While our re-brand aims to give us wider market appeal it in no means has diminished our commitment to work on projects and technologies with the goal of eliminating our consumption of non sustainable resources.

As a micro entity my role is cross functional involving all aspect of managing the business while also delivering on the promises we've made to our clients. Its a challenging role that often requires me to build upon existing, or quickly learn new skills to meet the requirements of the task at hand but I can honestly say it rarely feels like work.

On a day to day basis this could include meeting a new client to pitch our services, discuss a new project requirement, create a technical specification, statement of work, project plan and associated quotation for works involved. To sketching up concepts, designing mechanism, calculating forces, 3D modelling ideas, using CAE techniques to validate designs, and manage the development process through stage gates to deliver robust products fit for purpose.

We work closely with a few select freelancers and contractors to allow us to scale our resources up and down as each project requires. This allows us to ensure we stay competitive and have the right skills, at the right time as each project requires.

Our core services include;

For more information on the services we offer head over to the Form Lab website.

GF Genovate

Key Skills Mix

Company Name: Greenfrog Genovate

Website: https://www.genovatepowersolutions.com/

Job Title: Product Design & Manufacturing (Service)

Dates: July 2014 - August 2014

Location: Leeds, West Yorkshire, U.K.

Green Frog Genovate are specialists in the consultancy, design and delivery of power generation projects, offering a complete power backup solution for the public and private sector.
We provide complete solutions for all power generation installation needs. We supply, install and maintain diesel and gas generators across the UK, whether you need a single standby engine or a multi-engine power station.
Source: https://www.linkedin.com/company/genovatepowersolutions/

GF Genovate approached me to design, develop and manufacture a prototype battery storage system for a proof of concept product they're developing for emerging overseas markets. By utilising digital design tools such as computer-aided design & drafting #CADD & finite element analysis #FEA I was able to develop a quick to assemble, lightweight yet robust system capable of supporting the mass of the lead-acid batteries during transportation and installation whilst utilising stock steel profiles. No prototypes we're needed reducing the development time & project costs.

Kinneir Dufort

Company Name: Kinneir Dufort

Website: http://www.kinneirdufort.com/

Job Title: Mechanical Design Engineer (Contract)

Dates: November 2013 - August 2014

Location: Bristol, UK.

Key Skills Mix

"Kinneir Dufort is an award-winning integrated research, innovation, design and product development company with over 30 years’ experience helping companies discover, create, develop and realise tangible new products, brands and experiences.

We operate globally across many different sectors with some of the world’s largest brands and corporations, as well as SMEs and start ups, creating winning solutions in healthcare, consumer, business-to-business, defence and security. We have a multi-disciplined team with ISO 9001 and 13845 accreditation, allowing us to work at the forefront global medical device development.

Combining user-understanding with technical know-how, the expertise areas we offer encompass research, creative innovation, strategic branding, product design and development, prototyping, electronics & software and low volume manufacture."

Source: http://www.kinneirdufort.com/about

Working on site at both their Host Street office and Tech Centre in the north of Bristol I had the pleasure of working with some of the companies most talented designers and engineers, on a revolutionary smoking cessation portable electronic device for a global healthcare and medical devices company.

My role involved support of the product development process by providing the team with analytical data to back up the design and engineering decisions, including but not limited to;

Stress analysis of mechanical assemblies including non-linear spring & catch components.
Thermal analysis of composite micro heating element for maximum performance & efficiency.
Fluid flow analysis of multiple device configurations focusing on internal pressure for operation & optimal drug delivery.
Conjugate heat transfer analysis of multiple device configurations reducing design, build & test cycles leading on to PK (pharmacokinetics) study.
Development of test and validation system capable of quantifying the performance of microfluidic dosing mechanism.
Design and prototype LED optics suitable for injection moulding in line with industrial design concepts.
Performance testing of drug delivery system to meet vapor droplet specification.

Magnomatics

Key Skills MIx

Company Name: Magnomatics Ltd.

Website: http://www.magnomatics.com/

Job Title: Mechanical Design Engineer (Contract)

Dates: April 2013 - October 2013

Location: Sheffield, South Yorkshire, UK.

Magnomatics is a high technology engineering company that is developing and manufacturing products for many global industries based on its proprietary ground breaking magnetic gear technology.

Magnomatics have developed two derivative products based on magnetic gears, the Pseudo Direct Drive PDD® and MAGSPLIT®. The PDD is a very efficienct high torque low speed motor/generator highly suited to rail traction, actuation, fan motors, marine propulsion and wind power. MAGSPLIT is a very efficient power-split hybrid transmission and is being evaluated by a number of vehicle manufacturers. MAGSPLIT is very simple having just two rotating elements and has the added benefit of filtering torsional vibrations.

The company is active in many market sectors, including hybrid vehicles, renewables, marine propulsion, aerospace, rail, and oil & gas.

- http://www.magnomatics.com/

I began contracting for Magnomatics shortly after leaving Slipstream Engineering Design. As my first contract position I couldn't have asked for a better client, giving me the opportunity to get involved in a number of key projects. As a high tech dynamic engineering company it was clear to see that right first time was key to the success of the business, coupled with a technical and management team with a clear vision for getting their novel technology into all industries that could benefit from efficient drive technology.

My role focused on realising the technical direction of the lead engineers into manufacturable products suitable for customer technology demonstration & test validation. I predominantly worked on products in their PDD product group which included;

Wing flap actuator for an Italian aerospace OEM.
Lightweight, modular multi megawatt drive for a global renewable energy consultancy.
High utilisation in wheel electric vehicle (EV) motor for commercial vehicles.

In addition to working on PDD products I was also tasked with root cause analysis of a high speed turbo shaft failure using numerical & analytical techniques for a tier 1 global automotive OEM and a multi axis test rig for the static & dynamic testing of electrical machines suitable for torsional loads up to 6kNm & equivalent magnetic loads of up to 3kN.